Apparatus for layup placement

ABSTRACT

Method and apparatus for layup placement on a layup structure is provided. The method includes iteratively loading a layup for the layup structure on a support frame of a saddle module; aligning the saddle module with a pre-selected registration position corresponding to a predetermined application path on the layup structure; and impressing the layup into forced contact with the layup structure along the predetermined application path using a predetermined application force. The apparatus includes a plurality of saddle modules configured to operate in unison, wherein the plurality of saddle modules is configured to receive a pre-selected composite material layup.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. Pat. No. 9,770,871,filed May 22, 2007 and issued Jan. 21, 2010, and is related to U.S. Pat.No. 8,568,551 filed on May 22, 2007 and issued Jan. 21, 2010, which isincorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to aircraft production and,more particularly, to airframe fabrication using composite materials.

BACKGROUND

Modern commercial aircraft are fabricated using substantial amounts ofcomposite materials, which require manufacturing apparatus andtechniques different from those used with metal component production.Automated fiber placement (AFP) machines were developed for thefabrication of large aircraft, with a typical AFP machine using amandrel to place composite materials, usually as bundled composite fiberyarns, or tows, on the airframe. AFP mandrels can be massive, oftenweighing from 20 tons to over 100 tons, and are most efficient when usedin continuous rotation around the fuselage barrel. However, it often isnecessary to place one or more additional layers of composite materialson limited portions of the fuselage to reinforce certain locations, suchas cut-outs and openings for ports, hatches, doors, etc. Moreover, theseadditional layers may need to be placed with an orientation or directionangle different from the primary orientation of continuous fiberplacement. To place these additional layers, a typical AFP mandrel isstopped, repositioned, and restarted, leading to inefficiencies that maybe unacceptable in the commercial production of large transport-classaircraft.

As a result, there is a need for apparatus and methods by which one ormore additional layers of composite materials may be placed efficientlyon limited portions of a wing and/or airframe without limitation andwithout stopping, repositioning, or restarting a typical AFP mandrel.

SUMMARY

In one embodiment, a method for layup placement on a layup structure isprovided. The method includes iteratively loading a layup for the layupstructure on a support frame of a saddle module; aligning the saddlemodule with a pre-selected registration position corresponding to apredetermined application path on the layup structure; and impressingthe layup into forced contact with the layup structure along thepredetermined application path using a predetermined application force.

In another embodiment, an apparatus for layup placement on a layupstructure is provided. The apparatus includes a saddle module configuredto receive a pre-selected composite material layup, wherein the saddlemodule is configured to place the pre-selected composite material layupon the layup structure over a predefined application path using apredefined application force.

In yet another aspect, an apparatus for layup placement on a layupstructure is provided. The apparatus includes a plurality of saddlemodules configured to operate in unison, wherein the plurality of saddlemodules is configured to receive a pre-selected composite materiallayup.

This brief summary has been provided so that the nature of the variousembodiments may be understood quickly. A more complete understanding ofthe embodiments can be obtained by reference to the following detaileddescription of the preferred embodiments thereof in connection with theattached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow diagram of an aircraft production process, inaccordance with the present disclosure;

FIG. 2 is a graphical illustration of an integrated layup application,also in accordance with the present disclosure;

FIG. 3 is an illustration of multiple layups, which may be appliediteratively to a layup structure, in accordance with the teachings ofpresent disclosure;

FIG. 4 is a flow diagram representative of an layup application process,in accordance with an embodiment of the present disclosure;

FIG. 5 is a flow diagram depicting an embodiment of a saddle modulelayup application process in conjunction with the process embodimentdepicted in FIG. 4;

FIG. 6 is a graphical illustration of a layup placement apparatus, inaccordance with an embodiment of the present disclosure;

FIG. 7 illustrates a saddle module, which may be used by the apparatusin FIG. 6;

FIG. 8 illustrates a modular layup placement apparatus, in accordancewith another embodiment of the present disclosure;

FIGS. 9A-9F illustrate examples of layups which may be applied inaccordance with the teachings of present disclosure;

FIGS. 10A-10D illustrates a contoured-surface forming tool, which may beused in conjunction with disclosed apparatus and method embodiments; and

FIG. 11 illustrates multiple layups, which may be applied iteratively toa layup structure, in accordance with the teachings of presentdisclosure.

Embodiments of the present disclosure and their advantages are bestunderstood by referring to the detailed description that follows. Itshould be appreciated that like reference numerals are used to identifylike elements illustrated in one or more of the figures.

DETAILED DESCRIPTION

The present disclosure describes embodiments of a modular layupplacement apparatus and corresponding methods, capable of accommodatinga wide range of layup structure contours, geometries, sizes, andconfigurations.

As used herein, a “layup” refers to a shaped assembly, includingcomposite materials, having one layer (lamina) or multiple layers. Amultiple-layer layup may be fabricated in a stacked configuration, asandwich configuration, or a combination thereof. A composite materialmay be a fiber matrix material having fibers arranged and surrounded bya support matrix material. In general, a fiber can refer to any suitablefilamentary material, either natural or manmade, including, withoutlimitation, carbon filamentary material, graphite filamentary material,polymer filamentary material, metal filamentary material, or acombination thereof. In addition, a metal filamentary material mayinclude, without limitation, aluminum, stainless steel, titanium, oralloys, or organometallic combinations thereof. Fibers may be arrangedin a fiber system as whiskers, collimated filaments, fiber yarns, wovenfabric, ribbons, mats, or combinations thereof. One example of acomposite material can be a reinforced composite material that is acombination of two or more constituent materials, which differ inphysical properties, chemical properties, or both, which generallyretain their respective properties in composition, and which may actsynergistically to impart special properties to the resultant compositematerial. The terms “composite,” and “reinforced composite” can besynonymous. In modern airframe manufacturing, the constituent materialsgenerally include reinforcement material in the form of a fiber system,which is surrounded and maintained within a matrix system.

Fiber system reinforcement material may include, without limitation,glass fibers, carbon fibers, graphite fibers, metal fibers, or acombination thereof, which may be provided in numerous forms including,without limitation, a woven fabric, a non-woven fabric, a mat, a cloth,a scrim, a tape, a strand, a tow, or a combination thereof. In general,a tow is an untwisted bundle or yarn of generally parallel continuousfilaments, including continuous carbon fiber filaments, which may beused alone or as a constituent of a fabric, a cloth, a tape, orcombinations thereof. Typically, this yarn, and other material formsmade from such yarn, can be identified by the number of filamentsprovided in each tow. For example, a carbon tow designated “6K”typically constitutes 6000 continuous carbon filaments. Similarly, acarbon fabric may be fabricated from 6K carbon tows in one or both ofthe warp and the fill. Although a layup may be described in terms of acarbon or a graphite material, present embodiments also encompass alayup in which one or more lamina may be constituted of a metal or metalcomposite material.

Also, a support matrix can be a material suitably constituted forembedding a selected fiber system, including an organic matrix material,a metallic matrix material, an intermetallic matrix material, or anorganometallic matrix material. In one non-limiting example of a supportmatrix, a carbon fiber system may be embedded in a thermoset orthermoplastic material, such as toughened epoxy resin organic matrixmaterial. A metallic matrix material can be constituted of one or moremetals including, without limitation, aluminum, stainless steel,titanium, alloys, or intermetallic compounds, thereof. A non-limitingexample of a matrix system can be a resin matrix system. A resin matrixsystem can be an organic polymer or prepolymer, which may have thermosetor thermoplastic properties, and which may contain a wide variety ofcomponents or additives to influence handling and processing behaviorand physical properties. A resin matrix system also may be constitutedfor use as an adhesive, capable of producing surface attachment between,for example, adjacent composite material layers or a composite materiallayer and an airframe surface. An example of a commonly used resinmatrix system can be a polymerizable thermosetting resin, such as anepoxy polymeric resin. Typically, resin matrix systems may be identifiedin terms of a nominal resin cure temperature, the resin type, andspecial material characteristics.

However, the embodiments herein are not limited to layups fabricatedwith a resin matrix system, and other suitable matrix systems may beemployed. In addition, one or more layup lamina may be a layer of metal,or metal alloy, including, without limitation, aluminum or an aluminumalloy, stainless steel or a stainless steel alloy, titanium or atitanium alloy, magnesium or a magnesium alloy, or silicon carbide or asilicon carbide alloy. Also, one or more lamina may be fabricated froman intermetallic-matrix composite material, a metal-matrix compositematerial, or a ceramic composite material. Such matrix systems, andfunctional analogues, are well known in the art.

As used herein, a layup structure is a structure to which a layup may beapplied. One example of a layup structure can be an airframe, or aportion thereof, including, without limitation, a fuselage, a wing, acanard, a cone, a fin, a door, a radome, a nose, an empennage, anacelle, a strake, a spar, or a fairing. Another example of a layupstructure can be a forming tool including, without limitation, a mold ora mandrel. A mold forming tool may be employed in the fabrication of anangular airframe portion such as, without limitation, a wing, a canard,a door, a radome, a strake, a spar, a fairing, or a portion thereof.Similarly, a mandrel forming tool may be employed in the fabrication ofa cylindrical airframe portion including, without limitation a nose, acone, a door, a radome, a fuselage, an empennage, a nacelle, or aportion thereof. Of course, other forming tools may be employed, andother layup structures may be selected. For convenience, certainembodiments herein may be described with respect to an airframefuselage, although this is not to be taken as a limitation.

The layup structure may have a definable cross-sectional shape at eachpre-selected registration position along the reference axis. Anapplication width may describe a linear extent of a definable region ofa layup structure surface at a pre-selected registration point along thereference axis. The linear extent of an application width is orientedgenerally perpendicularly to the application direction and generallyalong the reference axis. An untapered portion of a layup structure mayexhibit a predetermined contour profile that remains substantiallyunchanged over the application width corresponding to a pre-selectedregistration point. However, the layup structure may be tapered alongthe reference axis, that is, have a varying cross-sectional shape, forexample, along the layup structure reference axis. Thus, a taperedportion of a layup structure may exhibit a predetermined contour profilevarying in three-dimensions over the extent of an application width.Accordingly, a pre-selected layup material may be configured to conformto a predetermined contour profile, which may vary in three dimensionsalong an application width corresponding to a pre-selected registrationpoint.

The layup placement apparatus herein may be configured in one or moreembodiments to place a layup fabricated from a pre-selected material ina definable spatial relationship on a structure, relative to a knownfiducial location, or “home,” within a corresponding spatial referencesystem. A fiducial location generally describes a known referencelocation that may be used by a human operator, or by a machine, toidentify boundary conditions within a common spatial reference systemand to identify selected locations in the spatial reference system withuniformly high precision. A workspace is a definable spatial referencesystem including a fiducial location.

By way of definition, to “correspond to” a known location is to be in adefined spatial relationship with that location. Also, registration isthe process of establishing correspondences between a known fiduciallocation and a particular plane or set of planes within the workspace.Such a plane may define a local frame of reference. A registrationposition is an identified location for which such a local frame ofreference has been established. Indexing is the process of establishinga point, or region, of operation within a local frame of reference; anindexed position is a point or region of operation so identified. Aregistration position may correspond to one or more indexed position(s)within a corresponding local frame of reference. As used herein, anindexed position, and the location of objects at the indexed position,may be made to correspond to a known fiducial location by making theregistration position correspond to the known fiducial location.Accordingly, an indexed position can correspond to a unique location onthe surface of a structure referenced to the known fiducial location inthe workspace.

In addition, the term “application” is made with reference to placing apre-selected layup material on the surface of a layup structurereferenced in the workspace. The pre-selected layup material may betreated to adhere to the layup structure surface after it is placed. Anapplication path can describe a definable region of the layup structuresurface over which the layup material may be applied; an applicationdirection can describe an orientation of an application path within theworkspace, from a start point to an end point; and an application ratecan describe time-referenced motion along the application path.Similarly, an application force can be a selectable force impressed uponlayup material being placed along the application path. The applicationforce can be impressed along the application path in the applicationdirection; however, the application force has a direction and anorientation that generally are different from the application direction.For example, the application force direction may be normal to theapplication direction over at least part of the application path. Ingeneral, an application path can be referenced to a selectableregistration position, and may be rectilinear or curvilinear.

“Inconsistencies,” as the term is used in the appropriate contextthroughout this disclosure, refers to the difference between one or moremeasured characteristics of a composite structure that has beenunaffected by exposure to external factors (including foreign objectdebris (FOD), thermal loads, structural loads, lightning, or electricalarcing) with the same one or more measured characteristics of acomposite structure that has been affected by exposure to the externalfactors. “Inconsistencies,” also includes the difference between one ormore measured characteristics of a composite structure manufacturedwithin design tolerances with the same one or more measuredcharacteristics of a composite structure manufactured beyond designtolerances.

FIG. 1 illustrates an integrated aircraft production process 100, inaccordance with embodiments of the present disclosure. As used herein,integrated aircraft production process 100 also may includemanufacturing, support, or both. Typically, process 100 includes apre-production phase (S102), a production phase (S104), and apost-production phase (S106). Pre-production phase S102 may includeaircraft design, subassembly, and component design (S110), and materielspecification and procurement (S120). Material specification andprocurement (S120) may include selection and procurement of componentsfabricated, or subassemblies manufactured, by third parties, withoutlimitation, vendors, subcontractors, or suppliers. Production phase S104may include component fabrication or subassembly manufacturing (S130),and aircraft assembly (S140). Pre-production phase (S102) and productionphase (S104) can be elements of an integrated manufacturing process(S105), including one or more of aircraft and component design,development, and simulation processes; material, component, andsub-assembly specification and procurement processes; automatedproduction planning processes; fabrication and assembly processes; andquality control processes.

Frequently, aspects of a modern aircraft production process, such asintegrated process 100, do not end with final assembly but may extendover the service life of an aircraft, involving iterative andinteractive collaborations between manufacturer, governmentalauthorities, customers and aircraft operators. Accordingly, integratedproduction process 100 can include post-production phase (S106).Post-production phase (S106) may include aircraft delivery andqualification (S150), and aircraft service (S160). Aircraft delivery andqualification (S150) may include providing an aircraft to customerspecifications, which may have changed after an aircraft, was assembled.Thus, delivery and qualification can include repair, modification, orrevision of one or more elements of an aircraft after delivery to acustomer or operator. Also, it may be desirable to perform amodification, a repair, or an upgrade to an aircraft in the serviceinterval between aircraft delivery and retirement. Therefore, aircraftservice S160 can include repair, modification, or upgrade of a portionof an airframe, including an airframe manufactured or assembled usingtraditional, pre-existing materials, components, or subassemblies.

Apparatus and methods embodied herein may be employed during integratedproduction process 100 in one or more of phases S102, S104, or S106. Forexample, components or subassemblies corresponding to production phaseS104 may be fabricated or manufactured in a manner similar to componentsor subassemblies procured during preproduction phase S102, and viceversa. Also, one or more of an apparatus embodiment, a methodembodiment, or a combination thereof may be of particular benefit duringproduction phase S104, for example, by substantially expediting assemblyof an aircraft. One or more of an apparatus embodiment, a methodembodiment or a combination thereof maybe of benefit duringpost-production phase 106, for example, without limitation to reworkduring delivery and qualification (S150) and/or maintenance and service(S160).

FIG. 2 illustrates an embodiment of integrated layup application system(ILAS) 200, in accordance with embodiments of the present disclosure.FIG. 3 illustrates predefined composite layups 301-305, as may be placedupon layup structure 300 by ILAS 200. ILAS 200 may be used in one ormore of phases S102, S104, or S106 of production process 100 in FIG. 1,and may employ layup application (hereinafter, saddle) system 210, layupstructure assembly 230, and verification-inspection system 240.Non-limiting examples of saddle system 210 may include layup placementapparatus (hereinafter) LPA 600, LPA 700, or LPA 800, in FIG. 6, 7, or8, respectively. A non-limiting example of a layup structure includeslayup structure 300 in FIG. 3, and layup structure 690 in FIG. 6, 7, or8. Advantageously, predefined composite layups 301-305 may beprefabricated in advance of application to layup structure 300, forexample, at a fabrication facility separate from an airframe fabricationand assembly facility in which an aircraft may be manufactured usinglayup structure 300. After fabrication, one or more of predefinedcomposite layups 301-305 may be provided as predefined composite layupkits, which may be inspected, stored, maintained, or delivered asinventory in a manner suitable for just-in-time manufacturing processes.In the context of FIG. 2, each composite layup 301-305 in FIG. 3 may bedisposed upon a respective carrier 631 as shown in FIG. 6 to form alayup kit, as represented by respective pre-selected layup kits 221-223.Predefined composite layups 301-305 may be pre-patterned compositelayups configured to conform to a contour of layup structure 300. One ormore of pre-patterned composite layups 301-305 may have withoutlimitation an aperture or a cutout, or be otherwise tailored forapplication to a predetermined portion of a particular layup structure300, for example, at a pre-selected registration position.

One or multiple layup kits 221, 222, 223 may be fabricated for generalapplication to a corresponding layup structure, as well as for aparticular portion of an airframe, for a particular airframe, for aparticular production run, or for a particular product line or productline variant, and thus may vary in size, shape, layers, composition, ora combination thereof. ILAS 200 also may include kit storage assembly220. Prefabricated layup kits may be selected to suit current productionneeds, and stored in kit storage assembly 220. Kit storage assembly 220can be configured to preserve pre-selected layup kits 221, 222, 223, forexample, by ambient temperature, humidity, gas composition, or layup kitposition control. As one non-limiting example, kit storage assembly 220may be implemented as a cassette-type robotic assembly configured todispense one of pre-selected layup kits 221, 222, 223, to saddle system210, under the control of a human operator, or of CNC manufacturingsystem 250. After receiving a pre-selected layup kit 221, 222, or 223,saddle system 210 may be positioned relative to layup structure 300 andmay cooperate with layup structure assembly 230 to apply thepre-patterned, predefined composite layup to a correspondingpredetermined portion of a layup structure. Layup structure assembly 230can hold a layup structure 300 in a predetermined fiducial location tofacilitate precise positioning and placing of a predefined compositelayup by saddle system 210 on the layup structure 300. One or both ofsaddle system 210 or layup structure assembly 230 may be controlled, atleast in part, by CNC manufacturing system 250.

FIG. 4 illustrates an embodiment of layup application process (LAP) 400.LAP 400 may be used, without limitation, by example LPA 600 in FIG. 6,by example LPA 700 in FIG. 7, or by example LPA 800 in FIG. 8. However,it is not required that LAP 400 be practiced by any of these LPA or thesaddle modules thereof. For expository purposes only, LAP 400 isdescribed relative to the elements depicted in FIG. 6.

LAP 400 may begin by selecting a pre-selected layup (S410) to be appliedto a pre-selected portion of a layup structure. In accordance with theforegoing, a suitable layup structure may be an airframe or a portion ofan airframe, or may be a forming tool, such as a mold or a mandrel. Forsimplicity, LAP 400 can be described, without limitation, with respect alayup structure 690, such as a fuselage. Layup structure 690 also may bea portion of an airframe other than a fuselage, a mold forming tool, ora mandrel forming tool. Saddle module 620 can be aligned with layupstructure 690 at a pre-selected registration position (S420), which isreferenced to a predefined fiducial location. Also, a predeterminedapplication path may be defined within a local frame of reference at thepre-selected registration position. For example, pre-selectedregistration position 675 can be referenced to fiducial location 650 andgenerally corresponds to predetermined application path 695 on layupstructure 690.

Once aligned, the pre-selected layup kit (layup 630 and carrier 631) maybe loaded (S425) onto support frame 628 of saddle module 620. Predefinedregistration position 675 may correspond to a predetermined layupstructure contour profile. Pre-selected layup 630 may correspond to therespective predetermined layup structure contour profile at thepre-selected registration position 675. In selected embodiments of LAP400, the pre-selected layup 630 can be a pre-patterned layup, configuredto conform to predetermined layup structure features corresponding tothe respective predetermined layup structure contour profile, at thepre-selected registration position. Pre-selected layup 630, typicallyhaving an initial flat form, can be placed on layup structure 690 alongthe contoured predetermined application path. When aligned with thelayup structure 690 at a corresponding predetermined registrationposition 675, pre-selected layup 630 may be applied (S430) to the layupstructure. Typically, the saddle module 620 retains the predefined layup630 until applied to layup structure 690 by way of carrier 631.

After being applied to the layup structure, it may be desirable toverify the layup application, for example, by inspecting (S435) thepositioning, configuration, or bonding, of layup 630 on the layupstructure. Inspecting may include, without limitation, layup positionverification, layup application inspection, or both. Positionverification may be accomplished using a verification sensor including,without limitation, an optical, optoelectric, or optomechanical sensor,such as a laser-based surface scanner. Application inspection may bewith respect to layup application to layup structure 690, to othercomposite material, or to a combination thereof. Inspecting may beperformed, for example, using an electrical, electro-optical, or opticalscanning system. Conveniently, suitable laser scanning systems are knownin the art of airframe fabrication, manufacturing, and assembly, and maybe used accordingly. Conveniently, laser-based scanning, sensing, andpositioning systems are well known in the art.

Importantly, LAP 400 can provide for rapid, iterative placement ofpre-selected layups 630 at one or more pre-selected registrationpositions 675 along the reference axis 695 of layup structure 690. Aftera first pre-selected layup is applied at a corresponding firstpre-selected registration position, a second pre-selected layup may beselected and applied at a corresponding pre-selected registration.

Additional layups 630 may be applied iteratively (S440). Indeed, as aprevious layup is being inspected, LAP 400 can provide for saddle module620 to be moved to a subsequent pre-selected registration position, fora subsequent layup corresponding to the subsequent pre-selectedregistration position to be selected and loaded onto saddle module 620,and for the subsequent pre-selected layup to be applied to the layupstructure as soon as it is practical to do so. A subsequent pre-selectedlayup may be placed at a different pre-selected registration position ormay be placed at the same pre-selected registration position of apredecessor. In this way, it may be possible to apply a subsequent layupwithin minutes of applying a preceding pre-selected layup, potentiallyincreasing layup application rates by one to two orders of magnitude,e.g., from 50 lbs/hr. to over 1000 lbs/hr.

Significantly, LAP 400 can be performed using high-precision automationtechniques. In addition, it is desirable to employ one or morepre-patterned layups as a pre-selected layup, further reducingpost-application trimming, manipulation, and re-work. Layup applicationinspection may be performed according to a pre-selected layupapplication standard, in which an applied layup may be examined forinconsistencies. In an implementation in which multiple layups may beapplied to layup structure 690, inspection (S435) may be performedwithout limitation after each layup is applied, after a pre-selectednumber of layups are applied, after all layups are applied, or in acombination of aforementioned verifications. A final inspection oflayups applied to the layup structure may be performed (S450)thereafter.

FIG. 5 generally depicts an embodiment of layup application method 500,by which pre-selected layup 630 may be applied to layup structure 690.Method 500 can be an implementation of layup application S430 in LAP 400of FIG. 4, in which the pre-selected layup kit (630, 631) may be aligned(S420) with layup structure 690. In addition to being aligned with thelayup structure, the pre-selected layup kit may be indexed (S510) in thelocal frame of reference, to correspond to a pre-selected indexedposition on layup structure 690, for example, pre-selected indexedposition 680 in FIG. 6.

After positioning, it may be desirable to actuate the saddle module(S520) to bring the layup kit proximate to the layup structure, suchthat a region of layup may be put into forced contact with a firstselectable indexed position (for example, 680, FIG. 6) of the layupstructure, using a predetermined application force. The first selectableindexed position (680) typically demarcates a starting application point(not shown) of the predetermined application path (for example, 695),corresponding to a pre-selected registration position (for example,675), with an ending application point (not shown) being located at asecond selectable indexed position (similar to 680) on the layupstructure 690. The predetermined application force can be orientedgenerally axially inward to the centerline 692 of the layup structure,although a predetermined application force having a different axialorientation may be applied, for example, as may be desirable to suit aparticular contour profile. Continuing the above example, saddle module620 may be actuated to bring a first region of layup 630 into contactwith a first selectable indexed position of layup structure 690, using apredetermined application force oriented generally in a predeterminedapplication force direction.

A moving region of pressure may be progressively applied along thepredetermined application path over a corresponding application widthuntil the second selectable indexed position is reached (S530). Themoving region of pressure impress a portion of the layup 630, proximateto the region of pressure 695A, into forced contact with a correspondingselectable indexed position (similar to 680) of the layup structure 690.The moving region of pressure 695A can be impressed using apredetermined application force, which can be oriented to apredetermined application force direction (for example, axially inwardstowards centerline 692, FIGS. 6 and 7). The moving region of pressure695A generally traverses the predetermined application path 695 at apredetermined application rate. Although the predetermined applicationforce can be oriented generally axially inward to the layup structurereference axis 692, in certain embodiments it may be desirable to applya predetermined application force having a different axial orientation,for example, as may be desirable to suit a particular contour profile.

Upon reaching the second selectable indexed position (for example, 680),the moving region of pressure 695A is released (S540) from the layup(i.e. application force is released). In general, it can be desirable touniformly impress the predetermined application force over thepredetermined application path 695, to selectively distribute thepredetermined application force over the moving region of pressure 695A,or both, which may result in a layup application that can besubstantially free of inconsistencies.

Without loss of generality, and with reference to FIGS. 6-8, predefinedreference system 660 may be illustrated as a three-dimensional spatialreference system, which may extend along longitudinal (X) axis 662,transverse (Y) axis 664, and vertical (Z) axis 666. Within predefinedreference system 660, there also may be defined horizontal (XY) plane661, transverse-vertical (YZ) plane 663, and longitudinal-vertical (XZ)plane 665. However, it must be understood that predefined referencesystem 660, including related spatial, axial, or planar constructs, areprovided for the purpose of illustration only, and that other constructsmay be used, including, without limitation, those representing a polarcoordinate reference system. For simplicity and without limitation, thepresent apparatus and method embodiments are illustrated with respect toan airframe structure, in particular, a commercial transport aircraftfuselage, although they are not limited thereto.

Turning to FIG. 6, exemplary layup placement apparatus (hereinafter) LPA600 may include fiducial base 610, registration frame 615, and saddlemodule 620, and may be used during the fabrication of layup structure690. Such fabrication may include selectively applying to (or,equivalently, placing on) layup structure 690 one or more pre-selectedcomposite material layups, such as layup 630, at defined positions alongthe layup structure length (X-axis 662). Desirably, fiducial base 610may be firmly affixed to facility foundation 605, thereby establishingpredefined fiducial location 650, and, by extension, a defined workspacecorresponding to predefined reference system 660. In general, layupstructure 690 is oriented within the defined workspace. In particular,predefined fiducial location 650 unambiguously demarcates a knownposition within the defined workspace, and forms the basis for reliableand repeatable determination of any point or region within the definedworkspace.

Accordingly, a human operator, or location-aware machine may usepredefined fiducial location 650 to position an object, e.g., saddlemodule 620, accurately within the defined workspace, relative to layupstructure 690, and to locate precisely desired points corresponding tolayup structure 690. The location-aware machine may be a robot, guidedby CNC system, such as CNC system 250 in FIG. 2. Layup structure 690 maybe held in a fixed position in the defined workspace, relative topredefined fiducial location 650, and may be longitudinally aligned withX-axis 662. A particular registration position may be selected alonglongitudinal (X) axis 662, with a corresponding local frame of referencegenerally being defined in transverse-vertical (YZ) plane 663. Inaddition, the local frame of reference may correspond to a particularlayup application path, with selectable indexed positions being definedtherewithin on layup structure 690.

Not only does selectability of saddle module registration positions andlayup indexed positions expedite the accurate application of predefinedlayups to layup structure 690, such selectability also facilitatesreconfiguration of embodiments of LPA 600 within a workspace, as mayoccur with a change in airframe size, configuration, material, orspecification. In accordance with the embodiments herein, LPA 600 may bereconfigured, yet remain fixed to fiducial location 650 andspatially-referenced to predefined spatial reference system 660. Inaddition, between manufacturing operations for different productionparts, LPA 600 may be reconfigured, and be referenced to a differentspatial reference system, for example, by fixing fiducial base 610 to adifferent fiducial location on foundation 605. In such an instance,re-referenced LPA 600 may be reconfigured, as previously described,within the newly-defined spatial reference system.

Layup structure 690 may be an elongated aeronautical structurelongitudinally enclosed, at least in part, by an outer envelope, orskin. Registration frame 615 may extend generally along reference axis662, for example a longitudinal axis, and may be securely attached to,and in alignment with, fiducial base 610, thereby facilitating theidentification and selection of registration positions. Saddle module620 can be engaged with registration frame 615 in alignment with aselectable registration position, such as pre-selected registrationposition 675, and can be oriented longitudinally in atransverse-vertical (YZ) plane corresponding to the selectableregistration position. Layup structure 690 may be characterized by arespective predetermined contour profile corresponding to eachpre-selected registration position 675 along reference axis 662. Apredetermined application path can be described at each selectableregistration position, such as at pre-selected registration position675, with predetermined application direction being defined on layupstructure 690 generally between a beginning application position and anend application position. Desirably, each of the beginning and endapplication positions are a selectable indexed position, for example,pre-selected indexed position 680.

Saddle module 620 may be configured to support and to retain layup 630,and can facilitate the application of predefined layup 630(alternatively, layup) to layup structure 690 along predeterminedapplication path 695, which may be defined at pre-selected registrationposition 675. Layup 630 may be in the form of, without limitation, asheet, a panel, a patch, or a skin doubler. Also, layup 630 may be madeof a suitable composite material, having a unilayer (uniply) ormultilayer (multiply) construction. Although typically flat prior toapplication, predefined layup 630 may be sized and shaped forapplication to a particular portion of layup structure 690, which may becontoured and/or tapered. Layup 630 also may include precut shapescorresponding to layup structure features, including without limitation,a port, a hatch, or a door. For example and without limitation, layup630 may be a preformed, vacuum-compacted, six-ply, composite laminateskin doubler intended to reinforce stress locations corresponding to acargo door opening on layup structure 690. Layup 630 may be orientedrelative to a selectable registration position along layup structure690, such as pre-selected registration position 675.

Layup 630 can be supported on carrier 631 to facilitate thepre-application handling of layup 630, and subsequent application oflayup 630 to layup structure 690. In general, carrier 631 can beconfigured to releasably attach to saddle module 620. Carrier 631 may bea flexible metal sheet shaped to receive layup 630, and configured todetach therefrom after layup 630 is placed on layup structure 690.Carrier 631 may have an indexing element configured to retain layup 630in a selectable orientation on saddle module 620, for example, in aselectable indexed orientation corresponding pre-selected indexedposition 680 on layup structure 690. Together, layup 630 and carrier 631may constitute a layup kit (such as 221 of FIG. 2), which kit may havebeen previously prepared in a location distant to the workspace.

In general, saddle module 620 may include articulated locator 622,saddle base 626, and support frame 628. Articulated locator 622 can belongitudinally oriented to transverse generally along reference (Y) axis664, for example, a transverse axis, and may be positioned beneath layupstructure 690, relative to axis 662, at pre-selected registrationposition 675. In certain embodiments, articulated locator 622 can beconfigured to include locator arms 624, 625, each being pivotablymounted on a respective proximal end to saddle base 626. Locator arms624, 625 typically are disposed, controlled, positioned, and operatedsymmetrically and complementarily, with respect to layup structure 690.However, in selected embodiments, saddle module may be configured topermit locator arm 624 to be controlled, positioned, and operatedindependently of locator arm 625. Support frame 628 can be attached torespective distal portions of locator arms 624, 625. In addition,support frame 628 can be configured to retain a layup kit 221 (e.g.,layup 630 releasably mounted on carrier 631) during manipulation and canprovide indexing of the layup kit, for example, using an indexingelement on carrier 631, so that layup 630 is constrained in a selectableindexed orientation relative to layup structure 690, on support frame628.

Advantageously, this indexing can be made to occur within the localframe of reference, as defined at pre-selected registration position675, such that a region on layup 630 may correspond to pre-selectedindexed position 680 on layup structure 690. Pre-selected indexedposition 680 generally corresponds to pre-selected registration position675 which, in turn, may be made to correspond to predefined fiduciallocation 650, so that the spatial location corresponding to pre-selectedindexed position 680 may be determined unambiguously. In general,locator arms 624, 625 can be adducted toward layup structure 690 so thatlayup 630 may precisely contact layup structure 690 relative topredefined fiducial location 650, for example, at pre-selected indexedposition 680. Pre-selected indexed position 680 may correspond to one ormore selected reference planes within predefined spatial referencesystem 660 including, without limitation, horizontal plane 661,transverse-vertical plane 663, longitudinal-vertical plane 665, a planecorresponding to a predetermined combination thereof, or any other planedefined within predefined spatial reference system 660.

Registration frame 615 can support saddle module 620, and can facilitateits repositioning along layup structure 690, relative to reference axis662. Typically, saddle module 620 can be transversely engaged withregistration frame 615. Beneficially, saddle module 620 may be moved,positioned, relative to predefined fiducial location 650, at aselectable registration position on registration frame 615, such as atpre-selected registration position 675. Saddle module 620 may be movedmanually along axis 662 to pre-selected registration position 675, andalso may be adapted for automated longitudinal positioning, for example,using a computer-controlled positioning machine. Once positioned, saddlemodule 620 may be firmly affixed to reference frame 615, for example bybolting, clamping, or otherwise securing, such that the movement ofsaddle module 620 may be substantially prevented.

Registration positions, such as pre-selected registration position 675,may be demarcated by mechanical and electronic methods known to the art,including, without limitation, indicia 617 affixed to registration frame615, mechanical indexing apparatus, or electrical, electro-optic, orelectromechanical position sensors. In selected embodiments, LPA 400 maybe configured to have multiple saddle modules 620 disposed along X axis662. In addition, registration frame 615 may be modularly configured sothat registration frame modules may be joined or removed along axis 662,thereby adapting the length of registration frame 615 to suit aparticular layup task or layup structure. Beneficially, registrationframe 615 may be configured with an open end to facilitate attaching andremoving additional saddle module 620. Thus, LPA 600 can be operated toplace layup 630 onto layup structure 690, relative to pre-selectedindexed position 680, along a predetermined application path 695 at apredetermined application force rate, and using a predeterminedapplication force applied. As described with respect to LPA 800 in FIG.8, LPA 400 may be configured to accommodate plural saddle modules, suchas saddle module 620, each capable of being moved to a respectiveregistration position. Typically, each moveable saddle module 620 may bepositioned at respective selectable registration positions 675, and eachmay be capable of holding a respective layup 630 at a respective indexedlocation 680 corresponding to the respective pre-selected registrationposition 675.

FIG. 7 illustrates an embodiment of saddle module 700, including saddlebase 710, locator assembly 720, support frame 730, locator motiveassembly 740, and force applicator assembly 750. Saddle module 700 maybe implemented, for example, as saddle module 620 in LPA 600 of FIG. 6.For the purposes of illustration, saddle module 700 is spatiallyreferenced to predefined spatial reference frame 660. Locator assembly720 may be an articulated locator including first locator arm 722 andsecond locator arm 723. For convenience, operation of locator 720 willbe described relative to first locator arm 722. However, each of locatorarms 722 and 723 may be identical in structure and complementary infunction, so that a description regarding first locator arm 722 also maypertain to second locator arm 723.

First locator arm 722 includes proximal locator arm portion 724 anddistal locator arm portion 726. Typically, locator assembly 720longitudinally corresponds to transverse (Y) axis 664, for example, whensaddle module 700 is deactuated, and locator arm 722 is laid generallyflat. Proximal locator arm portion 724 of first locator arm 722 may bepivotably mounted to saddle base 710 to allow distal locator arm portion726 to move in the local Y-Z plane 663. Also, locator assembly 720 mayinclude one or more indexing elements, such as an indexing pin 725,which may mate with an indexing element on carrier 791 to constrain thepositioning of layup 790 relative to layup structure 690, such thatlayup 790 can be aligned to a selectable indexed position, such aspre-selected indexed position 680 on layup structure 690. Layup 790 andcarrier 791 may be representative of layup 630 and carrier 631,respectively.

In general, support frame 730 can support a layup kit (e.g., layup 790and carrier 791) before and during application, and may include one ormore support straps 734 tensionably attached between first locator arm722 and second locator arm 723. Typically, each end of straps 734 isattached a respective locator arm by a keeper, such as keeper 732 onfirst locator arm 722. Straps 734 may be held in adjustable tension withthe keepers 732 by spring-loaded tensioners, for example, spring-loadedtensioners 736 may hold one end of straps 734 in adjustable tension withkeeper 732. Of course, other support structures may be attached tosupport frame 730, for example, a mesh, belt, or other flexible member,or any other form of tensioners may be used. Typically, support straps734 are configured to suitably support carrier 791 during applicationwhich, in turn, supports layup 790.

Locator motive assembly 740 can be linked to impart axial motion tolocator arm 722 with respect to axis 662. An exemplary locator motiveassembly 740 may include at least one pistoned cylinder 742 for eachlocator arm 722. Pistoned cylinder 742 may actuate locator arm 722 withpressurized fluid using known hydraulic or pneumatic techniques, or by acombination thereof. Thus, when actuated, locator motive assembly 740can drive locator arm distal portion 726 axially away from saddle base710, such that support frame 730 and, by extension, layup 790, is urgedtoward, and into forced contact with, layup structure 690. Typically,locator assembly 720 rises up towards layup structure 690 duringactuation to bring a region of layup 790 into contact with a firstselectable indexed position of layup structure 690, generally describinga starting application point on a corresponding predeterminedapplication path.

Force applicator assembly 750 may include at least one force applicator752 retained and guided generally longitudinally along locator arm 722.Exemplary force applicator 752 can include guide stanchion 754, to whichtruck 756 may be attached. Guide stanchion 754 can include guide mover755 that is configured to engage longitudinal locator arm guide track728. Guide mover 755 may be actuated to traverse locator arm guide track728 along a predetermined application path, in predetermined applicationdirection, and at a predetermined application rate, for example, by anelectric motor. In addition, multiple rollers 758 may be attached totruck 756 to facilitate movement along the predetermined applicationpath. Guide mover 755 also may employ fluid pressure, for example,pneumatic pressure, to adjust the position of guide stanchion 754 and toapply the predetermined application force to truck 756 through guidestanchion 754, along an axis normal to locator arm 722. Pressurizedfluid actuation may be beneficial where it is desired to impress layup790 upon layup structure 690 with a suitably large force.

Multiple rollers 758 may be attached to truck 756 to facilitate uniformmovement of force applicator assembly 750 over the layup kit.Conveniently, rollers 758 convey the predetermined application forcefrom truck 756 to carrier 791 and layup 790, and generate a moving, andgenerally uniform, region of pressure that brings layup 790 into forcedcontact with layup structure 690 at points along the predeterminedapplication path, for example, at pre-selected indexed position 680. Theforced contact between layup 790 and layup structure 690 can be madewith the predetermined application force being oriented generally in apredetermined application force direction. The predetermined applicationforce can be oriented generally axially inward to the centerline 692 oflayup structure 690, although force applicator assembly 750 may beoperated to apply a predetermined application force having a differentaxial orientation, for example, as may be desirable to suit a particularcontour profile. Rollers 758 can be spaced apart to define a suitablemoving region of pressure while traversing the predetermined applicationpath and, advantageously, may be configured to cooperate with carrier391 to distribute selectively the force conveyed from truck 756 to layup790.

Guide mover 725 can be configured to make smooth, progressive motionalong locator arm guide track 728, as it traverses the predeterminedapplication path corresponding to pre-selected registration position675. Guide mover 725 also can be configured to impress uniformly apredetermined application force on layup 790 in a predeterminedapplication force direction. The moving region of pressure may becontinuously applied to layup 790 over the span of the predeterminedapplication path, and may be released at a second selectable indexedposition describing the terminal application point of the correspondingpredetermined application path. After layup 790 is applied to theterminal application point, first locator arm 722 and second locator arm723 are released and causing distal locator arm portion 726 to beabducted from layup structure 690. After layup 790 is applied to layupstructure 690, carrier 391 can be retained on support frame 730, pulledaway from layup structure 690, and generally laid flat to facilitateremoval from saddle module 700. One or more additional layups may be soapplied subsequently. Because of the uniformly-made forced contact,layup 790 can be placed on layup structure 690 in a manner that issubstantially free of inconsistencies.

Although saddle module 700 may be configured to operate symmetrically,by which the positioning, operation, or function of locator arm 722 iscomplementarily matched by locator arm 723, certain embodiments ofsaddle module 700 may be configured to operate first locator arm 722independently from second locator arm 723. For example, locator arm 722may be operated to place a layup kit on a layup structure 690 proximateto first locator arm 722, while second locator arm 723 is disposed atrest. Similarly, certain embodiments of saddle module 700 may beoperated such that a first predetermined application force may beapplied by way of first locator arm 722 and a different, secondpredetermined application force may be applied by second locator arm723. Accordingly, saddle module 700 can use force applicator assembly750 to place layup 790 onto layup structure 690 along a predeterminedapplication path, using a predetermined application force, which may beoriented in a predetermined application force direction and applied at apredetermined application rate.

FIG. 8 illustrates an embodiment of LPA 800, which may be similarfunctionally to LPA 600 in FIG. 6. LPA 800 may include multiple saddlemodules 810-815, which may be longitudinally-joined and configured toact generally in unison. LPA 800 may be desirable, for example, toaccommodate the application of large layup 830 over a larger portion oflayup structure 690. Each of modules 810-815 can be structurally andfunctionally similar to saddle module 620 in FIG. 6 and saddle module700 in FIG. 7. Accordingly, LPA 800 can place a wider layup 830 (i.e.,covers a greater longitudinal portion of layup structure 690) than layup630, thus facilitating the rapid application of multiple large layups830 of precut, multi-ply composite material onto layup structure 690.LPA 800 also may include modular registration frame 850, which may beconfigured along axis 662 from one or more registration frames, similarto registration frame 615 in FIG. 6. Saddle modules 810-815 may bejoined to form a unitary saddle module, which may be moved in unisonalong reference axis 662 to predetermined registration position 875 onregistration frame 850. However, selected embodiments of LPA 800 mayemploy independently operable embodiments of saddle modules 810-815, forexample, to adjust to a longitudinally-varying contour profile of layupstructure 690.

Using an exemplary prototype of an LPA, such as LPA 800 having multiplesaddle modules 810-815, and using a method such as LAP 400 in FIG. 4, alarge prototype layup, such as layup 830, can be placed on abarrel-shaped structure, representative of aircraft layup structure 690,within a few minutes and in a manner that was substantiallyinconsistency free. The aforementioned prototype layup was disposed on aprototype indexed carrier, had approximate dimensions of twelve feet byfifteen feet, and included a six-ply composite layup, bearing precutfeatures. The exemplary prototype was capable of placing in excess ofabout 1000 lbs of composite materials per hour on the barrel, incontrast to conventional AFP machines and techniques, which may placeless than about 50 pounds per hour. Advantageously, the layups, used inaccordance with the apparatus and methods described herein, may be cut,finished, and inspected prior to application, potentially reducingmanufacturing costs by facilitating expeditious fabrication of themanufactured structure, with reduced material waste and post-applicationmanipulation. In addition, apparatus and methods embodied herein maypermit an AFP machine associated with airframe fabrication to operatemore continuously, thereby increasing overall manufacturing efficiency.

Moreover, a layup structure, after having a pre-kitted layup placedusing the disclosed apparatus, methods, or both, also may have one ormore layers of reinforced fibers wound around the layup and surroundingportions of the layup structure, allowing an AFP machine to operate withincreased continuity, relative to current apparatus and methods.

FIGS. 9A-9E depict example embodiments of a pre-selected layup kitincluding a multi-ply layup, suitable for application to layup structure690. Each of layup kits 900, 920, 940, 960, and 980, include carrier 990and release layer 991 on which the respective layups may be formed.Typically, the respective layups are formed on an obverse surface ofcarrier 990, with release layer 991 being interposed between carrier 990and the respective layup. One or more of the layup lamina in one or moreof layup kits 900, 920, 940, 960, or 980 may be fabricated from areinforced fiber-resin matrix material, an intermetallic-matrixcomposite material, a metal-matrix composite material, a ceramiccomposite material, or a metal or metal alloy material, although othersuitable matrix systems may be employed.

In. FIG. 9A, layup kit 900 is depicted as having a multi-ply layup withsix lamina 901-906 formed on an obverse surface of carrier 990. Layup(lamina 901-906) is arranged in a stacked configuration, with lamina 901being the uppermost lamina and lamina 906 being the lowermost lamina. Asfabricated on carrier 990, lamina 906 may be the first layup ply laiddown, proceeding in succession to lamina 901. As placed on a layupstructure, such as layup structure 690, lamina 901 may be disposed mostproximately to layup structure 690 and lamina 906 may be the outermost,relative to a layup structure surface.

FIG. 9B depicts an alternative embodiment in which layup kit 920includes a stacked, multi-ply layup having six lamina 921-926 formed onan obverse surface of carrier 990. In layup kit 920, lamina 921 may bethe uppermost lamina and lamina 926 may be the lowermost. As fabricatedon carrier 990, lamina 926 may be the first layup ply laid down,proceeding in succession to lamina 921. As placed on a layup structure,lamina 921 may be disposed most proximately to layup structure 690 andlamina 926 may be the outermost, relative to a layup structure surface.

In some applications, such as interiorly applied doublers, an abrupttransition may be acceptable. However, in other application, such aslayup applied to layup structure surfaces corresponding to an airframeexterior, it may be desirable to provide a smoothed surface over abruptlamina transitions, thereby improving interlaminar adhesion and otherproperties. A smoothed surface also may improve aerodynamiccharacteristics for external layups, such as a skin doubler. Examples ofan abrupt lamina transition may include a multi-ply, stacked layup or amulti-ply sandwiched layup. Layup kits 900 and 920 may be examples of alayup with a stacked configuration.

FIG. 9C illustrates layup kit 940, having six lamina 941-946 formed in asandwich configuration on an obverse surface of carrier 990. In layupkit 940, lamina 941 may be the uppermost lamina and lamina 946 may bethe lowermost. As fabricated on carrier 990, lamina 946 may be the firstlayup ply laid down, proceeding in succession to lamina 941. As placedon a layup structure, lamina 941 may be disposed most proximately tolayup structure 690 and lamina 946 may be the outermost, relative to alayup structure surface. Laminae 943 and 944 form a single-steppedtransition. Layup kit 940 provides a smoothed surface, for example, byoverlapping one or more layers, such as laminae 941 and 942 over theabrupt transition from laminae 943-944.

FIG. 9D illustrates layup kit 960, having six lamina 961-966 formed in asandwich configuration on an obverse surface of carrier 990. In layupkit 960, lamina 961 may be the uppermost lamina and lamina 966 may bethe lowermost. As fabricated on carrier 990, lamina 966 may be the firstlayup ply laid down, proceeding in succession to lamina 961. As placedon a layup structure, lamina 961 may be disposed most proximately tolayup structure 690 and lamina 966 may be the outermost, relative to alayup structure surface. Laminae 963 and 964 form a multi-steppedtransition. Layup kit 960 provides a smoothed surface, for example, byoverlapping one or more layers, such as laminae 961 and 962 over thetransition formed by laminae 963-964.

FIG. 9E illustrates layup kit 980, having six lamina 981-986 formed in asandwich configuration on an obverse surface of carrier 990. In layupkit 980, lamina 981 may be the uppermost lamina and lamina 986 may bethe lowermost. As fabricated on carrier 990, lamina 986 may be the firstlayup ply laid down, proceeding in succession to lamina 981. As placedon a layup structure, lamina 981 may be disposed most proximately tolayup structure 690 and lamina 986 may be the outermost, relative to alayup structure surface. Laminae 983 and 984 a-b form a single-steppedtransition. Laminae 984 a and 984 b present a layer discontinuity withinlayup kit 980. Lamina 983 provides an overlapping lamination which mayameliorate inconsistencies related to the layer discontinuity. Inaddition, layup kit 980 provides a smoothed surface, for example, byoverlapping one or more layers, such as laminae 981 and 982 over thetransition formed by laminae 983-984 a-b.

FIG. 9F illustrates layup kit 970, having six lamina 971-976 formed in asandwich configuration on an obverse surface of carrier 990. In layupkit 970, lamina 976 may be the uppermost lamina and lamina 971 may bethe lowermost. As fabricated on carrier 990, lamina 971 may be the firstlayup ply laid down, proceeding in succession to lamina 976. As placedon a layup structure, lamina 976 may be disposed most proximately tolayup structure 690 and lamina 971 may be the outermost, relative to alayup structure surface. Laminae 974-976 form a multi-steppedtransition. Layup kit 970 provides a smoothed surface, for example, byoverlapping one or more layers, such as laminae 973 over laminae974-976. Lamina 972 may be applied over laminae 973-976, and createanother discontinuity.

Lamina 971 may be provided as a smoothing layer over lamina 972, whichalso may have the practical effect of interlocking laminae 971-972 withlaminae 973-976. Laminae 973-976 may represent, for example, a fuselagelayup, and laminae 971-972 may represent, for example, a skin doublerlayup applied over the fuselage layup. Laminae 971-972 and laminae973-976 are depicted as being fabricated on a single carrier. However,apparatus and methods in the present disclosure contemplate a firstlayup being applied, at least in part, on a second layup, so thatlaminae 971-972 may be applied subsequently to laminae 973-976. In suchan application, laminae 973-976 may be initially applied to a layupstructure using a first layup kit, with laminae 971-972 representing asecond layup being applied to at least a portion of the first layup973-976.

In selected applications, it may be desirable to provide a forming toolhaving a surface modified to receive and/or accommodate the innermostlamina of a multi-play layup, such as the respective layups of kits 900,920, 940, 960, or 980, which may exhibit a blistered protruding, orbulging surface. In addition, the outermost lamina of layups, which maybe proximate to an outer aerodynamic surface of an aircraft, may beworked to smooth and fair the outer layup structure surface, and therebyreduce aerodynamic drag amongst other benefits.

In FIG. 10A contoured mandrel 1010 represents a forming tool having asurface modified to accept multi-ply layup 1020. Layup 1020 may besimilar to that provided with layup kit 920 in FIG. 9B, and have anabrupt, multi-stepped, discontinuous surface. Such a contoured-surfaceforming tool arrangement may be desirable where a multi-ply layup 1020,such as a skin doubler, may be placed on a door, a port, or a hatchaperture on an airframe portion corresponding to mandrel 1010, and whereit also is desirable to maintain the fair of the resulting airframesurface relative to the rest of the airframe structure. One or more ofLAP 400, process 500, or LPA 600, 700, or 800, may be used inconjunction with a contoured surface forming tool, such as mandrel 1010.

As shown in FIG. 10A, an embodiment has layup 1020 located directly ontomandrel 1020. Then the AFP may apply 1040 over the layup structure 300.Another embodiment shown in FIG. 10B, has at least one ply 1050 appliedto mandrel 1010 by AFP prior to locating layup 1020 and then the balanceof the plies 1045 applied by AFP. Another embodiment, shown in FIG. 10C,may have a plurality of plies 1060 applied by AFP to mandrel 1010 priorto location of layup 1020 and then the balance of the layers 1070applied by AFP. Another embodiment, shown in FIG. 10D, has substantiallyall of the plies 1080 applied to mandrel 1010 by AFP and the layup 1020applied plies 1080 and then at least on ply 1090 applied by AFP.

As shown in FIG. 10A, mandrel 1010 includes mandrel accommodation 1030to its outer surface to accommodate layup 1020. Mandrel accommodation1030 is sized and shaped to couple to the corresponding pre-selectedlayup 1020. Mandrel accommodation 1030 permits location of layup 1020 onlayup structure 300 according to the previously described embodimentsresulting in a smooth outer surface without blisters, bulges orprotrusions on the outer surface of the completed layup structure 300.The blisters, bulges or protrusions are located on the inner surface ofthe completed layup structure 300.

Mandrel accommodation 1030 may be located and/or oriented in anysuitable fashion to couple with its corresponding pre-selected layup1020. An embodiment as shown in FIG. 11, has five mandrel accommodations1130 (a-e) located on mandrel 1110.

Embodiments described above illustrate but do not limit the disclosure.It should also be understood that numerous modifications and variationsare possible in accordance with the principles of the presentdisclosure. Accordingly, the scope of the disclosure is defined only bythe following claims.

We claim:
 1. An apparatus for layup placement on a layup structure,comprising: a registration frame having a longitudinal axis; a saddlemodule engaged with the registration frame and comprising a locator armhaving a single end pivotably mounted to a saddle base of the saddlemodule, where the locator arm is configured to pivot in a planetransverse to the longitudinal axis of the registration frame, whereinthe saddle module is movable to selectable registration positions alongthe longitudinal axis of the registration frame and configured toreceive a pre-selected composite material layup, wherein the saddlemodule is configured to place the pre-selected composite material layupon the layup structure; and wherein the saddle module further comprises:a support frame tensionably attached to the locator arm and configuredto flexibly and releasably retain the pre-selected composite materiallayup; and a predefined application force applicable by the locator armand configured to bring the pre-selected composite material layup intoforced contact with at least one pre-selected indexed position on thelayup structure.
 2. The apparatus of claim 1, wherein the saddle moduleis configured to place the pre-selected composite material layup on thelayup structure over a predefined application path using a predefinedapplication force.
 3. The apparatus of claim 1, wherein the saddlemodule is configured to receive a layup kit comprising: a carrier andthe pre-selected composite material layup positioned on the carrier. 4.The apparatus of claim 3, wherein the carrier includes an indexingelement configured to retain the pre-selected composite material layupon the saddle module in a selectable indexed orientation correspondingto a pre-selected indexed position on the layup structure.
 5. Theapparatus of claim 1, wherein the layup structure has a layup structurecenterline generally corresponding to a layup structure reference axis,wherein a predefined application path corresponds to a pre-selectedregistration position along the layup structure reference axis, and thepredefined application path at the pre-selected registration positioncorresponds to a respective layup structure contour profile.
 6. Theapparatus of claim 1, further comprising a predetermined applicationforce applicable by the saddle module in a predetermined applicationforce direction normal to the locator arm.
 7. The apparatus of claim 6,wherein the predetermined application force is applied at apredetermined application rate.
 8. The apparatus of claim 1, furthercomprising: a fiducial base affixed to a predefined fiducial location ina predefined spatial reference system, wherein the predefined fiduciallocation demarcates a defined workspace in the predefined spatialreference system; and the registration frame attached to and inalignment with a longitudinal axis of the fiducial base, wherein thesaddle module is engaged with the registration frame at a pre-selectedregistration position corresponding to the predefined fiducial location,and a predefined application path corresponds to the pre-selectedregistration position, wherein the saddle module is configured to placethe pre-selected composite material layup on the layup structure overthe predefined application path using a predefined application forceapplied in a predetermined application force direction, and the layupstructure has a respective layup structure contour profile correspondingto the pre-selected registration position.
 9. The apparatus of claim 1,wherein the layup structure is for an aircraft assembled by a productionprocess, comprising: a pre-production phase; a production phase; and apost production phase.
 10. The apparatus of claim 9, wherein thepre-production phase comprises: selecting a component fabricated by athird party and the component is used in an aircraft assembly and anaircraft sub-assembly.
 11. The apparatus of claim 9, wherein thepre-production phase comprises: designing the layup structure for thelayup placement.
 12. The apparatus of claim 9, wherein the postproduction phase comprises: rework of an aircraft using the pre-selectedcomposite material layup for the layup structure.
 13. An apparatus forlayup placement on a layup structure, comprising: a registration framehaving a longitudinal axis; a plurality of saddle modules configured tooperate in unison, where at least one saddle module of the plurality ofsaddle modules is engaged with the registration frame and movable toselectable registration positions along the longitudinal axis of theregistration frame; and the at least one saddle module of the pluralityof saddle modules comprises an articulated locator including at leastone locator arm having a single end pivotably mounted to a saddle baseof the saddle module and pivotable in a plane transverse to thelongitudinal axis of the registration frame; wherein the plurality ofsaddle modules is configured to receive a pre-selected compositematerial layup and to place the pre-selected composite material layup onthe layup structure; and wherein the at least one saddle module furthercomprises: a support frame tensionably attached to the locator arm andconfigured to flexibly and releasably retain the pre-selected compositematerial layup; and a predefined application force applicable by thelocator arm and configured to bring the pre-selected composite materiallayup into forced contact with at least one pre-selected indexedposition on the layup structure.
 14. The apparatus of claim 13, furthercomprising a predefined application force applicable by the plurality ofsaddle modules and configured to place the pre-selected compositematerial layup on the layup structure.
 15. The apparatus of claim 14,wherein the predefined application force is applied over a predefinedapplication path corresponding to a layup structure contour profile. 16.The apparatus of claim 14, wherein the plurality of saddle modules isconfigured to receive a layup kit comprising a carrier and thepre-selected composite material layup positioned on the carrier, whereinthe carrier includes an indexing element configured to retain thepre-selected composite material layup on the plurality of saddle modulesin a selectable indexed orientation corresponding to a pre-selectedindexed position on the layup structure.
 17. The apparatus of claim 13,wherein the layup structure is for an aircraft assembled by a productionprocess, comprising: a pre-production phase; a production phase; and apost production phase.
 18. The apparatus of claim 17, wherein thepre-production phase comprises: selecting a component fabricated by athird party and the component is used in an aircraft assembly and anaircraft sub-assembly.
 19. The apparatus of claim 17, wherein thepre-production phase comprises: designing the layup structure for thelayup placement.
 20. The apparatus of claim 17, wherein the postproduction phase, comprises: rework of an aircraft using thepre-selected composite material layup for the layup structure.